Fertilizer compositions and methods of making and using same

ABSTRACT

Fertilizer compositions for plant production are described, comprised of decontaminated manure and  Bacillus  spores, preferably a humic acid derived from lignite and, optionally, one or more of N compounds, P compounds, K compounds, and combinations of two or more of these compounds. Preferred compositions are those wherein the ingredients are blended into an admixture resulting in a granular product. Other preferred compositions are those blended into an admixture resulting in a powdered product. Preferably, the ingredients are formed into hardened prills or pellets. Processes for production and use are also presented.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is generally related to the field of formulation and useof fertilizer compositions for agricultural use. More specifically, theinvention relates to fertilizer compositions that contain viableBacillus bacteria and decontaminated animal manure.

2. Related Art

One of the principal goals of agricultural science has been to invent aperfect fertilizer composition that is capable of optimizing food plantproduction when used at minimum application rates and that,subsequently, will not degrade or adversely affect the soil ecosystem.The present invention attains this goal.

It is well understood that nitrogen (N), the single most important plantnutrient, has been over used in modern agriculture in an effort toencourage maximum plant yields. Nitrogen in the form of soluble nitratesis particularly harmful to the environment since nitrates readily leachout of soil and cause pollution of ground and surface waters.

Technology that permits lower use rates of N while maintaining plantyields is required worldwide. The present invention provides suchtechnology by combining unique ingredients and processing them in such away as to arrive at potentiated fertilizer compositions capable ofeffecting substantial benefits in plant production. The novelty of thepresent invention relates to specific synergisms between the variousingredients and to the processing technology that renders suchingredients functional.

Microorganisms and animal manures have been utilized heretofore invarious fertilizer preparations in the past; yet none of these haveachieved substantial commercial success. This is because such prior arthas not proven to be economically efficacious under real farmingconditions. Technologies involving microbes and animal manures have beenplagued with inconsistencies due to the nature of these complex, organicsubstances.

Animal manure represents a significant resource that is under utilizedand, when not properly treated or disposed, causes substantialenvironmental damage. One significant limitation of manure is the grossmicrobial contamination present in fresh manure; typically, the totalnumber of viable microorganisms ranges between 1-10 billion per gram.The microbial species composition of fresh manure varies significantlyand it is not uncommon to find deleterious putrefying bacteria as wellas plant and animal pathogens. Using such manure for food plantproduction can pose health hazards and when added to soil along withbeneficial microorganisms, such as probiotic Bacillus bacteria, themicroorganisms contributed by the manure out grow the beneficialprobiotic microorganisms. This can lead to unintended, non-advantageousresults.

U.S. Pat. No. 6,228,806, Mehta, claims a biochemical fertilizer but nomention is made of using decontaminated manure as a source of theorganic ingredients. Other non-manure organics are indicated. A broadlist of microorganisms, listed by genera, is claimed in claim 10, whichincludes Bacillus, but this claim simply lists all the genera that maycontain beneficial microorganisms, not novel as they are listed as suchin numerous textbooks, and does not give any specific examples ofspecies with performance data. The need for microbial nutrients ismentioned in claim 14 but these must be part of the microorganismingredient, not the bulk organic ingredient as in my invention (wheredecontaminated manure feeds the Bacillus). Also, very important, I havediscovered that the decontaminated manure specified in my inventionuniquely stabilizes our product. Mehta offers claims that specify theneed to coat, or encapsulate, microorganisms with a water solublecoating, presumably for stability. This would be costly and unnecessaryaccording to my invention.

U.S. Pat. No. 6,312,492, Wilson, discloses improved fertilizer effect ofpoultry manure by adding sulfuric acid followed by drying. Wilsonteaches specifically the co-addition of cellulose containing materials.These would decrease the effectiveness of decontaminated manure in myinvention as they would not feed the Bacillus microorganisms and wouldtake up valuable space in the product.

U.S. Pat. No. 6,232,270, Branly et al., focuses on using Bacillusbacteria to enhance the effectiveness of chemical herbicides and listsevery imaginable Bacillus ever discovered, and claims they will allbenefit this purpose. Unfortunately, the use of chemical herbicides isteaching away from the present invention, which employs a more totalorganic approach where chemicals are ultimately eliminated.

U.S. Pat. No. 5,702,701, O'Donnell, claims the use of a unique strain ofBacillus laterosporus (BOD strain) to benefit plants. I have tested thisstrain and it is not the same as our CM-3 strain of Bacilluslaterosporus, for example, it does not adhere to plant roots and doesnot benefit actinomycetes and N-fixing bacteria in the rhizosphere.Nothing in the O'Donnell patent indicates how to compound B.laterosporus into a potentiated biofertilizer with the other activeingredients of our invention.

U.S. Pat. No. 6,174,472 describes a process of forming a pelletcomprised of at least sixty percent composted sewer sludge, up to fortypercent cellulosic plant material and up to fifteen percent nutrientmaterials and chemicals for soil enhancement and plant nutrition thatprovides a combination of both long and short term beneficiation of soiland herbage and has no pathogenic microbes above regulatory ranges. Thecomposted sewer sludge comprises primary sewer sludge admixed withcellulosic plant material that is thermally treated at temperaturesbetween 140 and 180° F. during composting to destroy mesophyllicpathogenic microbes and the viability of reproducible botanicalsincluding seeds, but leave most thermophilic soil enhancing microbes ina viable state. Additional fibrous cellulosic material and chemicals areadmixed with the composted sewer sludge and the mixture pelletized in athermal process that raises pellet temperature to between 140 to 180° F.The nutrient and chemical materials selectively comprise nitrogenousfertilizers, phosphate, potash, trace elements, herbicides, insecticidesand botanical chemicals. In the examples of the patent, three samples ofcomposted primary sewer manure are presented, with the statement that“all of the heavy metal tests and bacterial assays were well withinpresent regulatory standards of the Environmental Protection Agencyrequired for use of the composted product as an agricultural soilenhancer.” However, the levels of cadmium, arsenic, and lead are highenough to be a concern, and these composted primary sewer samples areprimarily useful only for ornamental plants and turf production, notfood production.

U.S. Pat. No. 6,025,187 describes bacterial complexes comprising atleast one non-pathogenic Bacillus and at least one non-pathogenicLactobacillus which essentially allow the conversion of inorganicnitrogen into organic nitrogen, in the form of bacterial proteins, whichallow the conversion of excrement into nitrogenous compounds (stablenitrogenous compounds and/or compost) and, particularly for waste havinga sufficient C/N ratio (in relation to the level of solids content),into non-polluting compounds rich in fulvic acid and humic acid, bydigestion and conversion of excrements, while at the same time removingthe associated pathogenic germs, in particular Clostridium, Bacteroides,colibacilli, Listeria, salmonellae and staphylococci. Unfortunately, thecomplexes disclosed in this patent require lactobacillus in addition tobacillus, and convert part of the excrement into humic acid, rather thanadding humic acid from an external source, wherein the source andcomposition of the humic acid may be strictly controlled.

There is a great but heretofore unmet need worldwide for technology thatpermits lower use rates of N while maintaining plant yields. The presentinvention provides such technology by combining unique ingredients andprocessing them in such a way as to arrive at potentiated fertilizercompositions capable of effecting substantial benefits in plantproduction. The novelty of the present invention relates to specificsynergisms between the various ingredients and to the processingtechnology that renders such ingredients functional.

SUMMARY OF THE INVENTION

In accordance with the present invention, fertilizer compositions thatcontain viable Bacillus bacteria and decontaminated animal manure arepresented. Optionally, these formulations preferably also contain humicacid and N—P—K substances, where N means nitrogenous ornitrogen-containing compounds (organic or inorganic), P indicatesphosphorous-containing (organic or inorganic compounds), and K indicatespotassium-containing (organic or inorganic compounds). Morespecifically, the invention concerns compositions comprising at leastone species of probiotic Bacillus bacteria that exert a positive effecton the yield of agricultural plants and/or reduce the nitrogenrequirements of agricultural plants, and animal manure that has beendecontaminated to reduce the concentration of undesirablemicroorganisms.

Thus, a first aspect of the invention is a fertilizer composition forplant production comprised of decontaminated manure and Bacillus spores,and preferably humic acid and, optionally, one or more of N compounds, Pcompounds, K compounds, and combinations of two or more of thesecompounds (for example two N compounds, an N compound with a P compound,two K compounds, or one each of N compound, P compound, and K compound).Preferred compositions are those wherein the ingredients are blendedinto an admixture resulting in a granular product. Other preferredcompositions are those blended into an admixture resulting in a powderedproduct. Preferably, the ingredients are formed into hardened prills orpellets. The decontaminated manure is preferably derived from manureselected from the group consisting chicken or swine manure, particularlyproduced without litter or bedding, and produced from animals notreceiving growth-promoting antibiotics in their feed.

Other preferred compositions of the invention are those wherein theBacillus spores are from strains of probiotic Bacillus bacteria capableof enhancing beneficial microbial populations within the rhizosphere.Preferably, the decontaminated manure has a total aerobic/facultativeviable plate count reduced by 2-4 logs (100 to 10,000 times) compared toraw manure.

Yet other preferred compositions of the invention are those wherein thehumic acid is derived from lignite.

As used herein, “humic acid” means a polymeric compound typicallycontaining the brownish-black pigment melanin, and can be obtained fromlignite. It is soluble in bases, but insoluble in mineral acids andalcohols. It is not a well-defined compound, but a mixture of polymerscontaining aromatic and heterocyclic strictures, carboxyl groups, andnitrogen, and is used in drilling fluids, printing inks, and plantgrowth. See Hawley's Condensed Chemical Dictionary, 12.sup.th Edition,(1993), page 608. As seen in the examples herein, not all humic acidsbehave in similar fashion.

Still other preferred compositions of the invention are those whereinthe N compounds are selected from the group consisting of urea, ammoniumsulfate, ammonium nitrate, ammonium phosphate, calcium nitrate,potassium nitrate, sodium nitrate; the P compounds are selected from thegroup consisting of ammonium phosphate, superphosphate, Ca(H₂PO₄)₂,tricalcium phosphate, phosphate salts of sodium or potassium, includingorthophosphate salts; and the K compounds are selected from the groupconsisting of KCl, potassium sulfate, potassium nitrate, and phosphatesalts of potassium, including orthophosphate salts.

Preferred compositions of the invention are those wherein thedecontaminated manure has a total aerobic/facultative viable plate countreduced by 2-4 logs (100 to 10,000 times) compared to raw manure.

Previously known methods relating to the treatment of manure have proveneither ineffective or expensive. The present invention discloses simple,inexpensive methods of decontaminating animal manure and, concomitantly,preserving its agronomic value while simultaneously rendering it intosuch a form that uniquely stabilizes advantageous probiotic Bacillusbacteria when they are admixed or further processed with decontaminatedmanure. This novel discovery was unexpected.

Thus, a second aspect of the invention is a method of making thefertilizer compositions of the first aspect of the invention, the methodcomprising the steps of:

a) treating raw manure to form a substantially decontaminated manure bya process selected from the group consisting of

i) pit composting the raw manure (preferably for 2 to 3 years) to make apartially decontaminated raw manure, and solar drying the partiallydecontaminated raw manure (preferably to reduce the moisture content toless than about 20 weight percent) to make the substantiallydecontaminated manure;

ii) reacting the raw manure with concentrated mineral acid (preferablyhydrochloric acid, sulfuric acid, phosphoric acid or nitric acid, themineral acid preferably added in sufficient quantity to reduce the pHbelow 3.0) to make the partially decontaminated manure, and subsequentlydrying the partially decontaminated manure (preferably to reduce themoisture content to less than about 20 weight percent) to form thesubstantially decontaminated manure;

iii) reacting the raw manure with a hypochlorite compound to make thepartially decontaminated manure, and subsequently drying the partiallydecontaminated manure to form the substantially decontaminated manure;and

iv) combinations of these; and

b) combining the substantially decontaminated manure with a secondcomposition comprising Bacillus spores to produce the fertilizercomposition.

Optionally, if the fertilizer composition produced by the methods of theinvention is desired to be in the form of prills or pellets, humic acidis added as a hardening agent, either in the second composition of step(b), or added as a third step (c). Preferably, the humic acid isselected from the group consisting of leonardite and potassium humate.The hypochlorite compound is preferably selected from the groupconsisting of either calcium hypochlorite, sodium hypochlorite, andmixtures thereof. The hypochlorite compound is preferably added at about0.5 to about 3.0 percent by weight.

The treating step of the inventive methods produces a “substantiallydecontaminated manure”, which means the decontaminated manure has atotal aerobic/facultative viable plate count reduced by a factor of fromabout 2 to about 4 logs (100 to 10,000 times) compared to raw manure.

Preferred methods of the present invention are those wherein theBacillus spores are prepared in water suspension prior to step (b) andthen added to the (preferably dry) ingredients of step (a) in the liquidsuspension.

The compositions of the invention preferably have Bacillus sporespresent in sufficient concentrations to effect a viable spore count ofbetween 10̂6 cfu to 10̂9 cfu per gram of dry composition. All preferredBacillus spores herein have been deposited at the American Type CultureCollection (“ATCC”), 10801 University Blvd., Manassas, Va. 20110-2209,under accession numbers indicated herein. The strains of B. subtilus andB. lichenformis were deposited Aug. 27, 2004, while the strains of B.laterosporous were deposited prior to Aug. 27, 2004. Preferably, theBacillus spores come from Bacillus selected from the group consisting ofBacillus laterosporus (ATCC PTA-3952), Bacillus laterosporus (ATCCPTA-3593), Bacillus licheniformis (ATCC PTA 6175), Bacillus subtilis(ATCC PTA-6174), and mixtures thereof. More preferably, the Bacillusspores come from mixtures of two or more of Bacillus laterosporus (ATCCPTA-3952), Bacillus laterosporus (ATCC PTA-3593), Bacillus licheniformis(ATCC PTA 6175), and Bacillus subtilis (ATCC PTA-6174).

It was further unexpected to discover that decontaminated manurefunctioned as an acceptable nutrient source for Bacillus growth andreproduction within the rhizosphere of plants; thus, creating a yieldenhancing and/or nitrogen sparing effect.

Thus a third aspect of the invention is a method of increasing the yieldof a plant while reducing the nitrogen effect, the method comprising thesteps of: a) supplying to a rhizosphere of a plant a sufficient amountof a composition of the invention to increase yield withoutsignificantly increasing the nitrogen effect; and b) maintaining contactbetween the rhizosphere of the plant and the composition for a timesufficient to enhance yield of the plant while reducing nitrogen effect.

Another aspect of the present invention relates to the discovery thathumic acid substances used in admixture with Bacillus bacteria anddecontaminated manure permit a prilled or pelleted fertilizer product tobe produced that has advantageous physical properties, especiallycompression strength. Thus, a fourth aspect of the invention is a methodof making a prilled or pelleted fertilizer product, the methodcomprising the steps of: a) producing a substantially decontaminatedmanure in accordance with the second aspect of the invention; b)combining the substantially decontaminated manure of step (a) with asecond composition comprising Bacillus spores to produce the fertilizercomposition; c) adding humic acid from an external source to thefertilizer composition to form a modified fertilizer composition; and d)forming a prilled or pelleted product, under conditions of temperatureand pressure suitable to produce the product.

A further aspect of the present invention is the discovery that certainprobiotic Bacillus species cause an increase in numbers of unrelated,yet beneficial, microbial species within the rhizosphere and,concomitantly, cause significant yield increases and/or nitrogen sparingeffects. Thus another aspect of the invention is a method of increasingconcentration of beneficial non-bacillus organisms in a rhizosphere, themethod comprising applying an effective amount of a composition of theinvention to a rhizosphere for a time sufficient to increaseconcentration of non-bacillus beneficial organisms in the rhizosphere,the non-bacillus beneficial organisms selected from the group consistingof actinomycetes and nitrogen fixing bacteria.

As stated herein, preferred fertilizer compositions of the invention areprills or pellet, i.e., solid forms of fertilizer. Since many areas ofthe world where increased food production is essential are also areaswhere there is hydrocarbon production, in particular natural gas, eitheractual or potential, integration of fertilizer and hydrocarbonproduction facilities is contemplated. In particular, natural gas orother hydrocarbon may be employed as fuel to create heated air, whichmay then be used to heat and dry raw manure in the production ofsubstantially decontaminated manure, and in drying wet fertilizercomposition after combination of decontaminated manure with wet secondcomposition comprising bacillus organisms.

Thus, another aspect of the invention is an integrated method forproduction solid fertilizer and hydrocarbons, comprising the steps of:a) producing a hydrocarbon composition from a source of hydrocarbon andusing at least a portion of the hydrocarbon composition as fuel to heat(by direct or indirect contact) an air stream to create heated air; b)contacting (directly or indirectly) a partially decontaminated rawmanure composition with a first portion of the heated air to form asubstantially decontaminated manure composition; c) combining thesubstantially decontaminated manure composition with an aqueouscomposition comprising bacillus spores to form a wet fertilizercomposition; and d) contacting (directly or indirectly) the wetfertilizer composition with a second portion of the heated air to form asolid fertilizer composition. If the air stream used in the step (a) hasbeen specially treated, for example to remove moisture, it may bedesirable to reuse this air stream. In other words, after exchangingheat in step (b) the first portion of the heated air stream may bereheated and used in step (d) as the second portion of heated air.

The above advantages and aspects of the invention will be furtherunderstood with reference to the following description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a logic diagram for production of solid fertilizerscompositions in accordance with the invention; and

FIG. 2 illustrates a schematic process flow diagram of an integratedfertilizer/hydrocarbon gas production facility.

DESCRIPTION OF PREFERRED EMBODIMENTS

Methods of Making Fertilizer Compositions

In accordance with the present invention, novel fertilizer compositionsare presented which improve the effectiveness of probiotic Bacillusmicroorganisms used to enhance plant yields and/or reduce nitrogenrequirements. The compositions of the present invention also preferablyimprove the effectiveness of Bacillus microorganisms utilized forbioinsecticide and biofungicide applications, and other agronomicapplications utilizing Bacillus bacteria. The discoveries of the presentinvention are capable of potentiating any Bacillus microorganism thathas advantageous applications in agronomy or agriculture.

A major aspect of the present invention involves the production offertilizer products in forms selected from the group consisting ofslurries, liquids, and solid forms. One particularly preferred solidfertilizer product of the invention is in the form of stable prills orpellets comprised of probiotic Bacillus microorganisms, decontaminatedanimal manure, humic acid substances, and, optionally, N—P—Kingredients.

Although it is possible to experience the benefits of the presentinvention by simply admixing these various ingredients, or by admixingonly the decontaminated manure and the Bacillus microorganisms, thenapplying said admixtures to soil as such, preferred embodimentsrecommend production of stable prills or pellets. Said prills/pelletspreferably have shape selected from the group consisting of round, oval,cylindrical and combinations of these, with diameter ranging from about1 to about 20 mm, more preferably ranging from about 2 to about 8 mm,moisture content ranging from about 1 to about 40 percent, morepreferably ranging from about 10 to about 20 percent, and compressionhardness ranging from about 5 to about 7 newtons.

The preferred solid products of the invention are preferably preparedusing means known within the fertilizer trade. One satisfactory,preferred method, which is illustrated in FIG. 1, involves granulatingthe dry ingredients followed by drying in a revolving drum drier thatproduces round or oval prills. However, due to the presence of probioticbacillus cultures, their production generally requires adjustments inthe operating parameters of the granulation and drying equipment fromthose typically used in the production of solid forms of fertilizer.These adjustments involve controlling product temperature and exposuretime (as generally taught in the examples herein) to insure thatoperating conditions are less severe compared to what would beexperienced in the production of less sensitive, conventional solidfertilizers. When the teachings of the present invention are properlyfollowed they result in the production of advanced technology fertilizerproducts that contains both organic and inorganic components and adefining content of probiotic Bacillus bacteria of high purity andprolonged shelf life. When fertilizer formulations of the presentinvention are applied to food plants, significant yield enhancementsresult and reductions in total nitrogen requirements can be achieved.

Dry ingredients, including decontaminated manure (ranging from about 20to about 70 weight percent of the solid product formulations), humicacids (preferably ranging from about 5 to about 25 weight percent of thesolid product formulations) and N—P—K compounds (preferably ranging fromabout 20 to about 60 weight percent of the solid product formulation, ifused) are ground to mesh size ranging from about 50 to about 400 mesh,more preferably ranging from about 100 to about 150 mesh. Theseingredients are blended (in no specific order), and then conveyed into agranulator where an aqueous spore suspension of the Bacillusmicroorganisms is sprayed onto the revolving dry ingredients.Preferably, from about 5 to about 15 percent of dechlorinated water isapplied by weight, said water containing all of the Bacillus sporesrequired to produce the batch. The moistened ingredients are thenconveyed into a rotating drying tunnel/drum where the temperature of theproduct is preferably maintained at temperature ranging from about 70 toabout 90° C. for a time ranging from about 1 to about 30 minutes, morepreferably from about 5 to about 15 minutes, subsequently, the productenters a cooling tunnel and is cooled rapidly to a temperature rangingfrom about 30 to about 40° C. The resulting prills, formed by therotation and drying process, are preferably screened for size and filledinto fertilizer bags, completing the process.

A novel aspect of the present invention is the degree of Bacillus purityin the fertilizer compositions of the invention. “Purity”, as used inreference to bacillus purity herein, means (total viablebacillus)/(total anaerobic+total facultative aerobic microorganisms).Preferably, the bacillus purity is above 60 percent, more preferablygreater than 80 percent, and most preferably greater than 90 percent.The preferred solid prills contain a high percentage of manureingredients (typically and preferably ranging from about 40 to about 60percent of the solid fertilizer composition), and contain a viableBacillus plate count (plated on tryptic soy agar after heating a sampleat about 80° C. for about 10 minutes followed by incubation at 32° C.for about 72 hours) that is greater than 90 percent of the total viableplate count (plated on tryptic soy agar without the heating step). Thesolid fertilizer composition of the invention in the form of prills, soproduced, preferably have an effective shelf life of at least 6 months,more preferably at least 12 months at temperatures ranging from about 25to about 35° C.

An aspect of the present invention allows fertilizer formulations to becustomized with respect to levels of N—P—K to suite various plants orsoil conditions. It is also possible to produce an organic fertilizerformulation that does not contain inorganic sources of N—P—K. Typicalformulations are set out in the example section of this disclosure,listed in Table 1 are some of the many N—P—K variations that arepossible within the scope of the present invention.

TABLE 1 N—P—K in Fertilizer Plant Composition¹ Rice-1 8-4-8 Rice-210-5-10 Rice-3 15-5-10 Leaf Vegetables 6-3-3 Tobacco 1-2-3 Watermelon1-0.7-1.5 Potatoes - 1st appl. 7-7-7 Potatoes - 2nd appl. 10-4-6 Corn &Wheat - 1st appl. 7-7-7 Corn & Wheat - 2nd appl. 10-4-6 Fruit Trees8-6-7, 7-5-9, 30-1-1 Non-leaf Vegetables 7-7-7, 6-3-3 Turf 7-7-7, 6-3-3,1-2-3 Ornamentals & Flowers 6-3-3, 7-7-7, 30-1-1 ¹wt percent N, wtpercent P₂O₅, wt percent K₂O

Bacillus Bacteria

The Bacillus spore suspension is preferably prepared by conventionaltechniques well understood by industrial microbiologists. Resultingspore suspensions preferably have a viable Bacillus spore count rangingfrom about 50,000,000 cfu/ml (5×10̂7 cfu/ml) to about 10,000,000,000cfu/ml (1×10̂10 cfu/ml), more preferably ranging from about 2×10̂8 toabout 2×10̂9 cfu/ml.

Any Bacillus microorganism that produces stable spores can be used inthe process of the present invention. Examples of such Bacillus speciesinclude but are not limited to: B. subtilis, B. laterosporus, B.licheniformis, B. uniflagellatus, B. cereus, B. coagulans, B. polymyxa,B. lentus, B. chitinosporus, B. pumilus, B. megaterium, B.thuringiensis, B. sphaericus, B. mycoides, B. popilliae, B.stearothermophilus, B. macerans, B. lentinmorbus, B. pasteurii, B.alvei, B. azotoformans, B. alcalophilus, B. circulans, B. brevis, B.badius, B. firmus, B. globisporus, B. larvae.

In preferred embodiments of the present invention, strains of Bacillusspecies that are capable of exerting a positive effect on the microbialcomposition of the rhizosphere are utilized. In particular, it isadvantageous to use strains that produce significant increases in thepopulations of Actinomycetes and nitrogen-fixing bacteria within therhizosphere. Experiments #1 and #2 demonstrate this effect in carrotrhizosphere soil. In Experiment #1, a strain of Bacillus laterosporus(ATCC PTA-3952) causes an increase of >1 log in Actinomycetes andnitrogen-fixing bacteria. In Experiment #2, a strain of Bacilluslicheniformis (ATCC PTA 6175) produces a similar result.

Manure Treatment

One of the critical discoveries of the present invention involves theunique application of animal manure in potentiating the effect of theBacillus microorganisms; specifically, chicken or swine manure, producedwithout litter or bedding, and produced from animals not receivinggrowth-promoting antibiotics in their feed. Chicken manure, for example,contains the following amounts of N, P (P₂O₅), and K (K₂O) in lbs. per1,000 U.S. gallons: N=80, P₂O₅=36, K₂O=96. In addition, there are manyorganic compounds that may serve as microbial nutrients. Fresh layerchicken manure, 13% dry matter content, contains over one billion or1×10̂9 cfu/gram of aerobic/facultative microorganisms, drying at 65° C.reduces this count, slightly, by approximately one-half. Such manure,nutrient content not-with-standing, cannot be used in the presentinvention. Manure with high concentrations of microorganisms willgrossly contaminate the fertilizer formulations of this invention andresult in poor growth of probiotic, Bacillus microorganisms in therhizosphere. Experiment #3 illustrates this point—B. laterosporus (ATCCPTA-3593) grown in sterile 1% chicken manure grows out to 1×10̂8 cfu/ml,proving that manure ingredients support the growth of Bacillus; however,in 1% raw chicken manure, B. laterosporus (ATCC PTA-3593) develops acount below 1×10̂5 cfu/ml. The present invention requires substantiallydry manure, moisture content preferably less than 20 weight percent,preferably less than 15 weight percent, chicken or swine origin, thathas a microbial plate count below ten million or 1×10̂7 cfu/gram(aerobic/facultative: total plate count on tryptic soy agar, 3 days, 32°C.), preferably below one million or 1×10̂6 cfu/gram. This represents a100 to 1,000 fold reduction, two-three logs, compared to the total countin fresh manure. When manure with a microbial content below one millioncfu/gram is used according to the teachings of the present invention,the resulting fertilizer formulations preferably have a Bacillus purityof 90 percent or greater. For lack of definitive terminology thisinventor will use the term “decontaminated manure” for manure that has areduced viable plate count according to the specifications stated above.

Experiment #4 illustrates the unique synergism that exists betweenprobiotic Bacillus bacteria and decontaminated manure, treated by thehypochlorite process of the present invention, when they are usedseparately and in combination in potato production; potato yields aresignificantly greater when the combination is used. It is apparent thatnutrients contained in the decontaminated manure stimulate the growth ofthe Bacillus within the rhizosphere environment leading to increasedpotato yields. A variety of techniques can be used to reduce viablemicrobial numbers in manure. One technique that has been usedsuccessfully in China involves long term composting in pits, for 2-3years, followed by solar drying for 2-3 weeks. This may not be practicalfor use in some other countries, due to higher labor costs, but isacceptable for the purposes of the present invention.

Experiment #5 sets out two alternate techniques involving chemicaltreatment followed by hot air drying that were developed for the purposeof the present invention. Both result in a dry manure product with amicrobial count below one million cfu/gram and both are relativelyinexpensive and fast, requiring less than 2-3 days to complete. It isnot the intention of the present invention to teach all the techniquesthat can be used to reduce the viable microbial content of manure, anymethod that renders the total microbial count below ten million cfu/gramand, most preferably, below one million cfu/gram, is acceptable for thepurpose of the present invention. It is possible that manure with highermicrobial contents, such as manure containing >10̂7 cfu/gram, may haveutility within the scope of the present invention, but this would not bewithin the preferred embodiments of the present invention.

A second, unexpected discovery of the present invention relates to thestabilizing effect that dry, decontaminated manure has on the viabilityof Bacillus spores to storage under adverse conditions (35 C at >80%relative humidity). This is clearly indicated in Experiment #6 where theeffect of blending spores of B. laterosporus (ATCC PTA-3952), B.licheniformis (ATCC PTA-6175), or B. subtilis (ATCC PTA-6174) indecontaminated chicken or swine manure is compared to a blend preparedin a dry N—P—K mixture and a blend containing manure and N—P—K. After 6months at 35 C/80% relative humidity, blends containing decontaminatedmanure had spore counts significantly higher (>one log) compared to theN—P—K mixture. This is relevant to the shelf-life of fertilizerformulations containing N—P—K ingredients that are prepared according tothe teachings of the present invention. I do not understand themechanism of this effect, it may relate to a protective effect renderedby certain complex organic compounds present in the treated manure. Itis well known in the trade that sterile soil is a protective medium forBacillus spores, manure decontaminated to the extent specified by thepresent invention may duplicate the effect of soil to some degree or,some heretofore unknown effect may be operating.

Humic Acid

Fertilizer prills made according to the present invention require ahardness rating of 5 to 7 newtons. Prills with hardness values below 5newtons readily break up during handling and shipment; prills withhardness values >7 are too hard and do not release nutrients effectivelyin the rhizosphere. Addition of humic acid derived from oxidizedlignite, or leonardite, is particularly effective as a hardening agentfor the purpose of the present invention. Potassium humate derived fromoxidized lignite is also effective. Humic acid addition levels, as apercent of complete fertilizer formulation, range between 5-25%depending on the composition of the formulation. Other known hardeningagents such as sodium bentonite or lignosulfonates do not perform aswell as humic acid for the purpose of the present invention. Humic acidsubstances derived from lignite also contain fulvic acid but at a lowerconcentration compared to humic acid. There is evidence presented inExperiment #7 that higher levels of fulvic acid may further benefit thephysical characteristics of prilled or pelleted formulations of thepresent invention.

A good source of humic acid is lignite from Black Hills Bentonite,L.L.C. of Mills, Wyo. Lignite is a pure, non causticized leonardite thathas a solubility of 70-75% in caustic solution and contains, typically,87% humic acid and 8% fulvic acid. A good source of humic acidcontaining higher levels of fulvic acid is available from leonarditeformations mined in New Mexico. A good source of potassium humate isavailable from LignoTech USA of Bridgewater, N.J.

Experiment #7 illustrates the importance of using humic acid substancesas a hardener in prilled fertilizer formulations produced according tothe present invention. When compared to sphagnum moss (peat moss) orsodium bentonite, the use of humic acid results in prills/pellets withsuperior hardness ratings.

Integrated Fertilizer/Hydrocarbon Gas Production

One preferred embodiment of the invention integrates the concepts ofhydrocarbon production and solid fertilizer production. As discussedherein, on aspect of making dry fertilizer compositions of the inventionis drying of the partially decontaminated manure, and drying of themixture of bacillus, decontaminated manure, and other optionalingredients, such as humic acid and N—P—K ingredients.

One integrated method for production solid fertilizer and hydrocarbonsis illustrated in FIG. 2. This preferred process 1 comprises the stepsof producing a hydrocarbon composition 2 from a source of hydrocarbon 4,and using at least a portion of hydrocarbon composition 2 as acombustion fuel with an air stream 6 in a burner or combustion chamber 8to form hot combustion products 10. Hot combustion products 10 exchangeheat in a heat exchanger 12 (by direct or indirect contact) with an airstream 14 to create a heated air stream 16. The source of hydrocarboncould be a refinery, chemical plant, oil or natural gas drilling orproduction site, and then like. A partially decontaminated raw manurecomposition 18 is delivered by suitable means 19 to a contacting means21, such as a tunnel/conveyor belt arrangement. The partiallydecontaminated raw manure composition 18 contacts (either directly orindirectly) a first portion of the heated air 20 in contacting means 21to form a substantially decontaminated manure composition 22.Substantially decontaminated manure composition 22 is then contactedwith an aqueous composition comprising bacillus spores, 24, deliveredfrom a conduit 25, to form a wet fertilizer composition 26. Wetfertilizer composition 26 is then contacted with a second portion ofheated air 28 in a rotating drier 30 to form a solid fertilizercomposition 32. Variations of this preferred process, including heatexchange between various streams, use of oxygen in the combustionprocess, and the like, are considered within the scope of the invention.For example, the air stream 6 could be preheated via heat exchange withhot combustion products 10.

Presentation of Experiments

Experiment #1—Rhizosphere Stimulation

B. laterosporus (ATCC PTA-3593), 5×10̂8 spores/ml, was applied to oneacre of carrots at planting, emergence, and one week post emergence at1.5 liters per application. Applications were made via drip irrigation,sandy-loam soil, southern California location. A control plot wastreated with water only. The same level of N—P—K fertilizer was appliedto both plots. At two weeks post emergence twelve samples of rhizospheresoil were taken from each plot and co-mingled aseptically. Theco-mingled samples were held at 5 C and analyzed within 24 hours forActinomycetes, nitrogen-fixing bacteria, and gram positive/gram negativeratio. Note: Bacillus bacteria are gram positive. Results are listed inTable 2. This data provides evidence that B. laterosporus (ATCCPTA-3593) stimulates the growth of beneficial microorganisms in therhizosphere.

TABLE 2 Sample Actinomycetes N-fixing Gram+/Gram− Control 1.3 × 10⁵  <1× 10³ 21:1 B. laterosporus 2.4 × 10⁶ 4.5 × 10³ 90:1 treated

Experiment #2—Rhizosphere Stimulation

B. licheniformis (ATCC PTA-6175), 4×10̂8 spores/ml, was applied to oneacre of carrots at planting, emergence, and one week post emergence at1.5 liters per application. Applications were made via drip irrigation,sandy-loam soil, southern California location. A control plot wastreated with water only. The same level of N—P—K fertilizer was appliedto both plots. At two weeks post emergence twelve samples of rhizospheresoil were taken from each plot and co-mingled aseptically. Theco-mingled samples were held at 5 C and analyzed within 24 hours forActinomycetes, nitrogen-fixing bacteria, and gram positive/gram negativeratio. Note: Bacillus bacteria are gram positive. The results arepresented in Table 3. This data provides evidence that B. licheniformis(ATCC PTA-6175) stimulates the growth of beneficial microorganisms inthe rhizosphere.

TABLE 3 Sample Actinomycetes N-fixing Gram+/Gram− Control   3 × 10⁴ <1 ×10³  27:1 B. licheniformis 2.8 × 10⁵  4 × 10⁴ 140:1 treated

Experiment #3—Bacillus Growth in Manure

B. laterosporus (ATCC PTA-3952) and B. licheniformis (ATCC PTA-6175)were tested for growth in 1% aqueous solutions of layer chicken manure:sterilized, decontaminated, and raw manure solutions were evaluated.Decontaminated manure was treated for 3 years in a compost pit and thensun dried for three weeks, it had a total microbial plate count of <10̂6cfu/gm. The raw manure used had a total microbial plate count of 3×10̂9cfu/gram. Bacillus cultures (5×10̂8 spores/gm) were inoculated into themanure solutions at 1% by volume and subsequently incubated at 34 C for48 hours; this was done in 250 ml baffled Erlenmeyer flasks shakenconstantly at 125 rpm. Total Bacillus plate counts and totalaerobic/facultative counts were made after 48 hours using tryptic soyagar incubated at 32 C for 72 hours. The Bacillus counts were made byfirst heating the sample for 10 minutes at 80 C to kill non-sporeforming bacteria and were then incubated aerobically to recover onlyBacillus. Results are listed in Table 4. This data provides evidencethat Bacilli grow well in chicken manure if it is sterilized ordecontaminated but do not grow well in raw manure due to its highconcentration of microbial contaminants.

TABLE 4 Non-Bacillus Sample Bacillus Count Count B. laterosporus in 9 ×10⁷/ml None 1% sterile manure B. laterosporus in <10⁵/ml >10⁹/ml 100 rawmanure B. laterosporus in 2 × 10⁷/ml <10⁷/ml 1% decontaminated manure B.licheniformis in 1.5 × 10⁸/ml   None 1% sterile manure B. licheniformisin <10⁶/ml >10⁸/ml 1% raw manure B. licheniformis in 9 × 10⁷/ml <10⁷/ml1% decontaminated manure

Experiment #4—Bacilli+Decontaminated Manure-Potato Trial

One acre plots of Chip variety potatoes, planted in central Utah, wereutilized for this experiment. One plot was treated with a Bacillus sporesuspension comprised of 4×10̂8 cfu/ml of B. laterosporus (ATCC PTA-3952)and 1×10̂8 cfu/ml of B. licheniformis (ATCC PTA-6175); one liter of thissolution was applied via a sprinkler irrigation system at planting, atemergence, and at one and three weeks post emergence. Another plot wastreated with 20 gallons of hypochlorite decontaminated layer chickenmanure (1% of 68% active calcium hypochlorite into 30% slurry of manure,reacted for 24 hours at 25 C) added in four divided applications as forthe Bacillus cultures. Another plot was treated with both the Bacillusspore suspension and the decontaminated chicken manure, same levels asindicated above. Finally, two plots were maintained as controls. Controlplots received water only. The base fertilizer program used for alltreatment and control plots was: 800 lbs 16-20-0-15 and 375 lbs of21-0-0-24 (these represent percentages of N—P—K—S with P and Kcalculated as P2O5 and K2O, respectively). The yields were measured atharvest and reported as # of 100 lb (CWT) sacks per acre—fourreplications were made per plot and the averaged results are reportedbelow. The data are listed in Table 5, which are average of replicates.This data is evidence that a synergistic response—maximum yield of529×100 lb sacks/acre—is realized when the Bacillus spore suspension isused in combination with decontaminated manure.

TABLE 5 Treatment Yield (CWT/Acre) Control #1 360 Control #2 390Bacillus Spore Suspension 460 Decontaminated Manure 407 Bacillus SporeSuspension + 529 Decontaminated Manure

Experiment #5—Manure Decontamination

A 30% water slurry of layer chicken manure (Minnesota farm) was treatedwith either calcium hypochlorite (1% of 68% active powder) orconcentrated mineral acid to pH 2.0. Four mineral acids were tested:HCl, H₂SO₄, H₃PO₄ and HNO₃. The treated samples were reacted for 24hours at 25 C and then dried to less than 15% moisture (65 C convectionoven). A sample of chicken manure composted in an eight-foot deep pitfor three years and then sun dried for three weeks was alsoevaluated—see Experiment #6 for the details of this pit compostingprocedure. Total aerobic/facultative viable plate counts were made ontryptic soy agar (32 C for 72 hrs) on the raw slurry (untreated),treated slurries, and dry products. Counts were made in triplicate,averages are reported in colony forming units/gram (cfu/gm). This datais presented in Table 6, and is evidence that all chemical treatments,after drying, result in a decontaminated manure product that contains atotal microbial plate count of less than 10̂6 cfu/gm. This result is alsoachieved by long term pit composting followed by sun drying.

TABLE 6 Sample Total Microbial Plate Count (cfu) 30% Raw Slurry 4.4 ×10⁸/gm 30% Slurry - Hypochlorite 1.3 × 10⁶/gm treated 30% Slurry - pH2.0 treated 1.7 × 10⁶/gm with HCl 30% Slurry - pH 2.0 treated 1.5 ×10⁶/gm with H2SO4 30% Slurry - pH 2.0 treated 1.8 × 10⁶/gm with H3PO430% Slurry - pH 2.0 treated 1.4 × 10⁶/gm with HNO3 Dry Slurry -Hypochlorite   6 × 10⁵/gm treated Dry Slurry - pH 2.0 treated   8 ×10⁵/gm with HCl Dry Slurry - pH 2.0 treated   7 × 10⁵/gm with H2SO4 DrySlurry - pH 2.0 treated   9 × 10⁵/gm with H3PO4 Dry Slurry - pH 2.0treated   6 × 10⁵/gm with HNO3 Pit Composted/Sun dried   7 × 10⁵/gm

Experiment #6—Bacillus Storage in Decontaminated Manure Versus N—P—K

Swine manure and layer chicken manure were decontaminated by pitcomposting (separate pits for each manure type) for three years in 8 ftdeep×16 ft wide pits, approximately 10% top soil, organic matter content6%, was added during the composting process by layering it on the manureas it was added to the pits. Typically, it would take the first year tofill the pits and two additional years to insure that various microbialprocesses would properly compost and reduce the viable microbial contentof the manure. Pits were loosely covered to prevent rain from enteringand/or excessive dehydration. The total microbial plate count on the rawmanure ranged from 10̂9 to 10̂10/gram on both manure types. After threeyears of composting the plate counts ranged from 10̂6 cfu/gram to 10̂7/cfugram on both manure types. Subsequently, the composted manure was sundried, on the ground, in layers approximately 1-2 feet deep; the dryingtime depended on the weather and sunshine intensity but averaged 3-4weeks. The viable microbial plate count on both types of manure, afterdrying, was at or below 10̂6 cfu/gram. The moisture contents were below15%. Manure, decontaminated as above, was blended with Bacillus spores(three different probiotic Bacillus species were examined separately) bymixing a liquid preparation of the spores into the dried manure so thata viable spore count of 2-6×10̂7 cfu/gram was achieved; if the sporesuspension contained 2-4×10̂9 cfu/gram, the moisture contribution to thedry mixture from the added spore suspension was about 1%. Forcomparison, the same Bacillus species (liquid spore suspensions) wereblended with a dry N—P—K mixture, typical of what is used in fertilizerformulations of the present invention (110 parts urea+170 parts superphosphate+40 parts KCl), and N—P—K+decontaminated manure containing 50%by weight of each. All blends were plated for total viable Bacillusspores/gram and then stored in the dark, 35 C/80% relative humidity, for6 months; subsequently, total viable Bacillus spores/gram weredetermined.

Bacillus Viable Spores/Gram—Procedure

The dry samples containing Bacillus spores are mixed in steriledistilled water, 1 part dry sample+9 parts water. This mixture is heatedat 80 C for 10 minutes and cooled rapidly, this procedure killsmicrobial vegetative cells but not Bacillus spores. The heated sample issurface streaked, at various dilutions, onto tryptic soy agar plates.Agar plates are then incubated, upright, at 32 C for 72 hours. Countsare made in triplicate, averages reported.

The following Bacillus cultures were examined:

-   B. laterosporus (ATCC PTA-3952) code below=B. lat.-   B. lichenformis (ATCC PTA-6175) code below=B. lich.-   B. subtilis (ATCC PTA-6174) code below=B. sub.

Manure Codes:

DSM=Decontaminated Swine Manure NPK=Dry N—P—K Blend

DCM=Decontaminated Chicken Manure

DSM+NPK=50/50 Mix

DCM+NPK=50/50 Mix

Results are reported in Table 7. This data is evidence thatdecontaminated manure exerts a protective, stabilizing effect on theshelf life of Bacillus spores admixed with said manure. By contrast,N—P—K fertilizer compounds exert a destabilizing effect when admixedwith Bacillus spores. Finally, mixtures of decontaminated manure andN—P—K compounds demonstrate the same stabilizing effect asdecontaminated manure alone.

TABLE 7 Spores/gram at 6 mo. Sample Spores/gram initially @ 35 C./80% RHB. lat. + DSM 4 × 10⁷ 4 × 10⁷ B. lich. + DSM 6 × 10⁷ 7 × 10⁷ B. sub. +DSM 3 × 10⁷ 2 × 10⁷ B. lat. + DCM 5 × 10⁷ 6 × 10⁷ B. lich. + DCM 6 × 10⁷8 × 10⁷ B. sub. + DCM 2 × 10⁷ 2 × 10⁷ B. lat. + NPK 4 × 10⁷ 3 × 10⁶ B.lich. + NPK 7 × 10⁷ 4 × 10⁶ B. sub. + NPK 2 × 10⁷ 9 × 10⁵ B. lat. +DSM + NPK 4 × 10⁷ 3 × 10⁷ B. lich. + DSM + NPK 6 × 10⁷ 4 × 10⁷ B. sub. +DSM + NPK 3 × 10⁷ 3 × 10⁷ B. lat. + DCM + NPK 5 × 10⁷ 4 × 10⁷ B. lich. +DCM + NPK 5 × 10⁷ 6 × 10⁷ B. sub. + DCM + NPK 2 × 10⁷ 1 × 10⁷

Experiment #7 Humic Acid Effect on Prill Hardness

Fertilizer formulations, consistent with the teachings of the presentinvention, produced according to the formulation set out in Example 1,were produced for this experiment. The effect of different sources ofhumic acid were examined with respect to prill compression strengthmeasured in newtons. Sodium bentonite was also examined as a controlsubstance (non-humic substance). The humic acid ingredients wereincluded at 180 parts per 1050 parts of total ingredients. Specifics ofthe humic acids tested:

1) Humic acid from oxidized lignite—high fulvic acid content (HA-HF).

2) Humic acid from oxidized lignite—low fulvic acid content (HA-LF).

3) Humic acid in the form of potassium humate (PH)

4) Sphagnum peat moss containing humic acid (SPM).

5) Sodium bentonite, 325 mesh, a non-humic acid substance (SB).

The results are listed in Table 8. This data demonstrates that humicacids from oxidized lignite and potassium humate promote advantageoushardness values, humic acids in the form of sphagnum moss produceborderline hardness, and non-humic acid containing substances such assodium bentonite do not produce acceptable hardness.

TABLE 8 Binding Ingredient Prill Hardness (newtons) HA-HF 6.5 HA-LF 6.0PH 6.0 SPM 5.5 SB <5.0

The novel fertilizer formulations of the present invention can besuccessfully produced by anyone skilled in the art of fertilizerproduction. The present invention is not limited in scope to followingthe embodiments disclosed below. Within the broad field of fertilizerart and science there are production options open to those skilled inthe trade that may yield an equivalent result to those presented herein;for example, substitution of a pelletizing technique for the prillingprocess of the present invention would be considered a violation of therights of the inventor and the assignee. The uniqueness of thediscoveries of the present invention cannot be compromised by trivialsubstitutions that do not add to the technical merits of the presentinvention.

Production of Prilled Fertilizer Products

Decontaminated Manure Ingredient

Dry ingredients including decontaminated manure, humic acid, and N—P—Kcompounds (if used) are ground to 100-150 mesh, blended, and thenconveyed into a granulator where an aqueous spore suspension of Bacillusmicroorganisms is sprayed onto the revolving dry ingredients. Thedecontaminated manure must have a total viable plate count (totalaerobic+facultative microorganisms plated on tryptic soy agar, 32 C, 72hrs) of less than 10̂7 colony-forming-units (cfu)/gram. Most preferably,to effect a purity rating of 90% or greater (measured as % Bacillusbacteria contained within the total viable plate count ofaerobic/facultative microorganisms), said decontaminated manure shouldhave a viable plate count of less than 10̂6 cfu/gram and a moisturecontent below 15%. Acceptable methods for decontaminating manure areindicated in Experiment #5.

Chicken manure from layer chickens is one preferred type of manure,swine manure from animals on antibiotic free feed is also acceptable. Acombination of layer chicken and swine manure has been used successfullyin the art of the present invention and is specified in Example #1. Thesole use of layer chicken manure is specified in Example #2. Examples #1& 2 use manures that were decontaminated by pit composting as detailedin Experiment #6. The layer chicken manure used in Example #3 wasdecontaminated by pH adjustment to pH 2.0 with HCl followed byconvection air drying at 65 C, described in detail in Experiment #5. Anexample of hypochlorite decontaminated manure, used successfully in apotato field trial, is presented in Experiment #4. All of these manuredecontamination methods, unique to the present invention, can beregarded as preferred embodiments.

Manure from ruminant animals such as cattle and sheep, or from broilerchickens, is not generally useful for the purpose of the presentinvention because it usually contains a high percentage of non-nutritivesubstances such as sawdust, rice hulls, straw or other forms of litterand bedding. The art and science of the present invention does not ruleout the use of these manure types if they can be obtained free ofundesirable substances and rendered below 1×10̂7 cfu/gram with respect tototal, viable, aerobic/facultative microorganisms.

The percentage of decontaminated manure, contained within the total ofdry ingredients utilized, ranges from 20-70% by weight depending on theintended application of the formulation being produced. Preferably,formulations will contain 30-60% of decontaminated manure; theformulations presented in Examples 1-3 fall within this range.

Decontaminated manure provides a novel, dual effect with respect to thepresent invention. First, it acts to stabilize the probiotic Bacillusspores within the formulation which would otherwise be unstable in thepresence of N—P—K ingredients (see Experiment #6). Second, it acts tostimulate the growth of the probiotic Bacillus bacteria in both labcultures and field trials resulting in higher yields of plants such aspotatoes (see Experiments #3 & 4).

Humic Acid Ingredient

The humic acid ingredient of the present invention acts to promote thehardness of prills/pellets—this is set out in Experiment #7. Humic acidproducts that are derived from lignite coal, more specifically oxidizedlignite, usually come in mixtures with fulvic acid; they are acceptablefor the purpose of the present invention. A good source of oxidizedlignite that suites the purpose of the present invention is availablefrom Black Hills Bentonite. LLC of Mills, Wyo.—called leonardite, it hasa typical humic acid content of 86-87% and a fulvic acid content of 8%(referred to as HA-LF in Experiment #7). A source that has a highercontent of fulvic acid, about 30%, is available from leonarditeformations in New Mexico (referred to as HA-HF in Experiment #7). Thequantity of humic acid substance that is required for the purpose of thepresent invention ranges from 5-25%, by weight of the total dryingredients, and depends on the requirements of the specificformulation; the quantities indicated in Examples 1-3 fall within thisrange.

N—P—K Ingredients

These are optional. Addition of conventional N—P—K ingredients toformulations of the present invention allows for the production ofcomplete fertilizer products. Such a product can be used as a solesource of fertilizer in many applications, or, as an augmentingfertilizer used together with conventional chemical fertilizers.

In situations where the formulations of the present invention are usedto augment existing chemical fertilizers, it is common to discover thatthe total amount of N required, and in some cases P and K as well, canbe reduced with the achievement of equal or better results. Thebiofertilizer properties of the present invention are responsible forthis effect.

The chemicals commonly used in agriculture to provide sources ofnitrogen (N), phosphorus (P), and potassium (K) are not generallycompatible with the probiotic Bacillus bacteria specified in thisdisclosure. Fortunately, the stabilizing effect of the decontaminatedmanure ingredient offsets this effect—see Experiment #6.

Examples of suitable N—P—K ingredients that can be used in formulationsof the present invention include but are not limited to: Urea,superphosphate, Ca(H2PO4)2, ammonium sulfate, ammonium nitrate, ammoniumphosphate, calcium nitrate, KCl, orthophosphate salts of sodium orpotassium, potassium sulfate, potassium nitrate, sodium nitrate, andtricalcium phosphate. It is also within the scope of the presentinvention to fortify formulations with elemental sulfur, sulfurcompounds, or trace elements if a particular situation demands theiruse.

The total amount of N—P—K ingredients added to a particular formulationmust be balanced against the weight requirements of the decontaminatedmanure and humic acid substances as specified above. Generally, in thoseformulations where N—P—K ingredients are indicated, inclusion rates willbe 20-60%. This is the range in Examples #1 & 2 where the respectiveN—P—K levels are 6-3-3 and 8-4-8.

Bacillus Spore Suspension Ingredient

About 5-15% of de-chlorinated water is applied by weight to the dryingredients, said water contains all of the Bacillus spores required toproduce a batch; preferably, the Bacillus spores are contained in 10%,calculated by weight of the total dry ingredients, of de-chlorinatedwater. The Bacillus solution is sprayed onto the dry ingredients as theyrevolve within a granulator, or, alternatively, an agglomerating dishset at an angle. The spray is through a nozzle that disperses thesolution in medium-fine droplets over an area about 1 ft. in diameter.The moistened ingredients are then conveyed into a rotating dryingtunnel where the temperature of the product is maintained at 70-90 C for8-16 minutes as it moves through the tunnel; preferably, the product ismaintained at 80 C for a transit time of 8-10 minutes. Subsequently, theproduct enters a cooling tunnel and is cooled to 30-40 C within 8-10minutes. The resulting prills, formed by the rotation and dryingprocess, are screened for size and filled into fertilizer bags,completing the process. Typical fertilizer prills produced according tothe above preferred embodiments have a Bacillus plate count between2-9×10̂7 cfu/gram, a hardness rating of 5.5-6.5 newtons, moisture contentof 12-16%, Bacillus purity of >90%, diameter of 2-6 mm, and shelf-lifeof 6-12 mo. at 35 C. A photograph of fertilizer prills producedaccording to the above specifications is attached to this disclosure.

The Bacillus spore suspension can be prepared by conventional techniqueswell understood by industrial microbiologists. Resulting sporesuspensions should have a viable Bacillus spore count of between100,000,000 cfu/ml (=1×10̂8 cfu/ml) to 10,000,000,000 cfu/ml (=1×10̂10cfu/ml), a typical satisfactory count for the practice of the presentinvention is 500,000,000 cfu/ml (=5×10̂8 cfu/ml). For purposes of thepresent invention a suitable method of preparing a spore suspension, forany of the Bacilli listed in the Summary of the Invention, is asfollows:

A good microbiological medium suitable for the cultivation of Bacillusis prepared in baffled Erlenmeyer flasks sterilized at 121 C under 15psig for 30 minutes or until rendered sterile. Tryptic soy broth (TSB)is a suitable growth medium as is Schaeffer's Sporulation Medium asreferenced in Biology of Bacilli (Doi, et al. Butterworth-Heinemann,1992). It is desirable to under fill the flasks to optimize aerationduring shaking; 200 ml of medium works well in a 4 liter flask. Theflask is fitted with a sterile filter cap that allows the contents tobreathe without becoming contaminated. The sterile medium is inoculatedfrom a slant culture on tryptic soy agar (a slant with good growth ismelted and poured into the flask). The inoculated medium is shaken on arotary, orbital shaker at 100-200 rpm at 32 C for 48 hours. Most Bacilliwill be 90% sporulated by 48 hours and a concentration of 5×10̂8/ml iseasily achieved with most species. The three species of Bacillus used inExamples #1-3 were prepared in the above manner but scaled up to 1,000liters. Scale up parameters are as follows:

A 1,000 liter aerobic fermentor (or larger) is utilized. The fermentormust be equipped for in-place sterilization at 121 C/15 psig, able to beaerated with sterile air at 1 volume air/minute/volume of fermentorcontents, temperature controlled and pH monitored. Although industrialgrade fermentation ingredients can be used, commercial tryptic soy broth(TSB) from Difco Laboratories or BBL Laboratories is satisfactory.Depending on the efficiency of the fermentation equipment, it may beadvantageous to prepare the TSB at 1.5 or 2.0 times the strengthrecommended on the label. The medium is prepared in the fermentor, or ina separate vessel, and charged raw into the fermentor. It is thensterilized at 121 C, cooled to 32 C, and inoculated at 1% by volume fromshake flasks prepared as above. Sterile air is constantly sparged intothe inoculated medium at one vol./min./vol. fermentor contents. Theinitial pH is adjusted to between 6.8-7.2, if necessary, using sterile50% NaOH or concentrated HCl. The fermentor is agitated constantly at100+rpm while being held at 32 C for 48 hours. At 48 hours the contentsof the fermentor are adjusted to pH 7.0 with the neutralizing compoundspreviously mentioned, the fermentor contents can then be used directlyto prepare the formulations of the present invention as set out inExamples #1-3.

Example #1

Preferred Embodiment Formulation—6-3-3 Vegetable Fertilizer

A microbial active fertilizer formulation containing organic, inorganic,and viable microbial cultures is prepared according the presentinvention. Layer chicken manure and swine manure, 50% by weight of each,was decontaminated by anaerobic/facultative composting for three yearsin an 8 ft. deep pit, amended with 10% top soil that was layered ontothe manure as the pit was filled during the first year and then held,loosely covered, for two more years at which time it was removed fromthe pit and dried to below 15% moisture in the sun, for three weeks,while layered on the ground in piles 1-2 feet deep. Said manure, afterdrying, was determined to have a total viable plate count(anaerobic/facultative count on TSA/32 C./72 hrs.) of 7×10̂5 cfu/gram.Prior to treatment said manure had a total viable plate count of >1×10̂9cfu/gram; therefore, the pit composting/sun drying decontaminationprocedure reduced the total viable plate count by a minimum of threepowers of ten, or three logs.

Separate aerobic fermentations were carried on two probiotic species ofBacillus bacteria, each species was grown separately. Bacilluslaterosporus (ATCC PTA-3952) and Bacillus licheniformis (ATCC PTA-6175),strains that enhance the numbers of beneficial microorganisms in therhizosphere (see Experiments #1 & 2.), were grown in sterile tryptic soybroth (TSB) in 1,000 liter aerobic fermentors for 48 hours at 32 C whilecontinually agitated at 150 rpm and continually sparged with sterile airat 1,000 liters/minute. At 48 hours the pH was adjusted to 7.0 witheither NaOH or HCl and the liquid spore suspensions were cooled to 20 Cand held until used. For the purpose of the present example, a blend wasprepared from the two spore suspensions: 80% by volume of B.laterosporus was blended with 20% by volume of B. licheniformis and theresulting spore count of the blend was determined to be 8×10̂8 cfu/ml (1ml=1 gram). This blend was used to inoculate the formulation of thepresent example during the granulation step described below.

TABLE 9 Ingredient Amount in Kg Wt. %* Decontaminated Chicken + SwineManure 500 50 Humic Acid (from oxidized lignite)** 180 18Superphosphate, Ca(H2PO4)2 170 17 Urea 110 11 KCl 40 04 Bacillus sporesuspension 50 kg 1050 kg 100% *Only dry ingredients included **Fulvicacid <9%

The total mixed and ground dry ingredients were conveyed onto arevolving agglomerating (granulating) conical dish, operated at a 45degree angle, and the Bacillus spore suspension (diluted 50% withde-chlorinated water) was sprayed on at the rate of 10% by weight of thedry ingredients. Subsequently, the moistened ingredients were conveyedinto a revolving drying tunnel where the product was dried and formedinto prills (2-6 mm diameter). The air temperature in the drying tunnelranged from 230-250 C, the product temperature never exceeded 80 C. Thedrying tunnel/drum was 90 feet long by five feet wide and was custombuilt so no commercial brand can be given. Transit time in the dryingtunnel was 7-10 minutes followed by an equal amount of time in thecooling tunnel that immediately followed the drying tunnel. Productarrived at the screening belt at 30-40 C where prills less than 2 mm indiameter were rejected. Subsequently the prilled product was filled into20 kg fertilizer bags. The product specifications are listed in Table10.

TABLE 10 Product Specifications: Bacillus Spore Count: 3.8 × 10⁷cfu/gram (representing 95% recovery) Bacillus as % of Total Plate Count:96% Moisture Content: 14% N—P—K rating: 6-3-3 (calculated as % N, %P₂O₅, % K₂O) % Organic Matter: 68% Prill Diameter: 2-6 mm, 4 mm averagePrill hardness: 6 newtons Bacillus Spore Count after 6 Mo. at 35 C.: 3.7× 10⁷/gram Recommended Use Rate for Vegetables: 800-1,200 lbs/acre as acomplete fertilizer

Example #2

Preferred Embodiment Formulation—8-4-8 Rice Fertilizer

A microbial active fertilizer formulation containing organic, inorganic,and viable microbial cultures is prepared according the presentinvention. Layer chicken manure was decontaminated byanaerobic/facultative composting for three years in an 8 ft. deep pit,amended with 10% top soil that was layered onto the manure as the pitwas filled during the first year and then held, loosely covered, for twomore years at which time it was removed from the pit and dried to below15% moisture in the sun, for three weeks, while layered on the ground inpiles 1-2 feet deep. Said manure, after drying, was determined to have atotal viable plate count (anaerobic/facultative count on TSA/32 C./72hrs.) of 9×10̂5 cfu/gram. Prior to treatment said manure had a totalviable plate count of >1×10̂9 cfu/gram; therefore, the pit composting/sundrying decontamination procedure reduced the total viable plate count bya minimum of three powers of ten, or three logs.

An aerobic fermentation was carried on two probiotic strains ofBacillus, the strains were grown together in the fermentor butmaintained separately in shake flasks which served as the inoculum forthe fermentor. Bacillus laterosporus (ATCC PTA-3952) and Bacilluslaterosporus (ATCC PTA-3593), a species that enhances the numbers ofbeneficial microorganisms in the rhizosphere (see Experiments #1 & 2.),were grown in sterile tryptic soy broth (TSB) in 1,000 liter aerobicfermentors for 48 hours at 32 C while continually agitated at 150 rpmand continually sparged with sterile air at 1,000 liters/minute. At 48hours the pH was adjusted to 7.0 with either NaOH or HCl and the liquidspore suspensions were cooled to 20 C and held until used. The resultingspore count of this two strain culture was determined to be 5×10̂8 cfu/ml(1 ml=1 gram). This blend was used to inoculate the formulation of thepresent example during the granulation step described below.

A dry mix of the ingredients listed in Table 11 was prepared and groundto pass through a 150 mesh screen.

TABLE 11 Ingredient Amount in kg Wt. %* Decontaminated Chicken Manure350 35 Humic Acid 100 10 (from oxidized lignite)** Superphosphate,Ca(H2PO4)2 266 26.6 Urea 157 15.7 KCl 127 12.7 Bacillus spore suspension50 kg 1050 kg 100% *Only dry ingredients included **Fulvic acid <9%

The total mixed and ground dry ingredients were conveyed onto arevolving agglomerating (granulating) conical dish, operated at a 45degree angle, and the Bacillus spore suspension (diluted 50% withde-chlorinated water) was sprayed on at the rate of 10% by weight of thedry ingredients. Subsequently, the moistened ingredients were conveyedinto a revolving drying tunnel where the product was dried and formedinto prills (2-6 mm diameter). The air temperature in the drying tunnelranged from 230-250 C, the product temperature never exceeded 80 C. Thedrying tunnel/drum was 90 feet long by five feet wide and was custombuilt so no commercial brand can be given. Transit time in the dryingtunnel was 7-10 minutes followed by an equal amount of time in thecooling tunnel which immediately followed the drying tunnel. Productarrived at the screening belt at 30-40 C where prills less than 2 mm indiameter were rejected. Subsequently the prilled product was filled into20 kg fertilizer bags. The product specifications are listed in Table12.

TABLE 12 Product Specifications: Bacillus Spore Count: 2.4 × 10⁷cfu/gram (representing 96% recovery) Bacillus as % of Total Plate Count:95% Moisture Content: 14.4% N—P—K rating: 8-4-8 (calculated as % N, %P₂O₅, % K2O) % Organic Matter: 45% Prill Diameter: 2-6 mm, 4 mm averagePrill hardness: 5.5 newtons Bacillus Spore Count after 6 Mo. at 35 C.:2.4 × 10⁷/gram Recommended Use Rate for Rice: 50-200 lbs/acre as aco-fertilizer with urea

Example #3

Preferred Embodiment Formulation—Top Dress 30-1-1 Fertilizer

A microbial active fertilizer formulation containing only nitrogenousingredients and viable microbial cultures was prepared according thepresent invention. Layer chicken manure was decontaminated by treatmentat pH 2.0 with concentrated hydrochloric acid; approximately 1%hydrochloric acid (containing 35% HCl) was added to a 30% slurry ofmanure, with agitation, until pH 2.0 was achieved. It was then reactedfor 24 hours before being dried in a drum dryer at 65 C until a moisturecontent below 15% was achieved. The total viable plate count on theuntreated manure was >10̂9/gram; after reaction with hydrochloric acidand drying, the total plate count was reduced to 8×10̂5/gram whichrepresents a reduction in count of greater than 1,000 fold (plated onTSA/32 C./72 hrs.).

An aerobic fermentation was carried on a probiotic strain of Bacillussubtilis (ATCC PTA-6174). The strain was grown in a 1,000 literfermentor inoculated from a TSB shake flask culture, multiple shakeflasks served as the inoculum which was added at 1% of the workingvolume of the fermentor. This is a strain of Bacillus subtilis that hasproven to be antagonistic to plant pathogenic fungi. The strain wasgrown in sterile tryptic soy broth (TSB) in the fermentor for 48 hoursat 32 C while under agitation at 150 rpm and sparging with sterile airat 1,000 liters/minute. At 48 hours the pH was adjusted to 7.0 witheither NaOH or HCl and the liquid spore suspension was cooled to 20 Cand held until used. The resulting spore count of this culture wasdetermined to be 7×10̂8 cfu/ml (1 ml=1 gram). This blend was used toinoculate the formulation of the present example during the granulationstep described below.

A dry mix of the ingredients listed in Table 13 was prepared and groundto pass through a 150 mesh screen.

TABLE 13 Ingredient Amount in Kg Wt. %* Decontaminated Chicken Manure300 30 Humic Acid 100 10 (from oxidized lignite)** Urea 600 60 Bacillusspore suspension 50 kg 1050 kg 100% *Only dry ingredients included**Fulvic acid >25%

The total mixed and ground dry ingredients were conveyed onto arevolving agglomerating (granulating) conical dish, operated at a 45degree angle, and the Bacillus spore suspension (diluted 50% withde-chlorinated water) was sprayed on at the rate of 10% by weight of thedry ingredients. Subsequently, the moistened ingredients were conveyedinto a revolving drying tunnel where the product was dried and formedinto prills (2-6 mm diameter). The air temperature in the drying tunnelranged from 230-250 C, the product temperature never exceeded 80 C. Thedrying tunnel/drum was 90 feet long by five feet wide and was custombuilt so no commercial brand can be given. Transit time in the dryingtunnel was 7-10 minutes followed by an equal amount of time in thecooling tunnel which immediately followed the drying tunnel. Productarrived at the screening belt at 30-40 C where prills less than 2 mm indiameter were rejected. Subsequently the prilled product was filled into20 kg fertilizer bags. The product specifications are listed in Table14.

TABLE 14 Product Specifications: Bacillus Spore Count: 3 × 10⁷ cfu/gram(representing 86% recovery) Bacillus as % of Total Plate Count: 95%Moisture Content: 14.4% N—P—K rating: 30-1-1 (calculated as % N, % P₂O₅,% K₂O) % Organic Matter: 45% Prill Diameter: 2-6 mm, 4 mm average Prillhardness: 6.5 newtons Bacillus Spore Count after 6 Mo. at 35 C.: 2.9 ×10⁷/gram Recommended Use Rate for Plants: 100-400 lbs/acre for top Dressapplications

Example #4

Improved Vegetable Yields—Field Trials

The 6-3-3 formulation from Example #1 (indicated as Bio-6-3-3) wascompared to an inorganic 6-3-3 product (indicated as CK-6-3-3) as afertilizer for a variety of vegetables. The inorganic product containedthe same N—P—K ingredients as the formulation of Example #1 only theywere incorporated into a non-biologically active carrier (sodiumbentonite). Trials were carried out in sandy-loam soil with an organicmatter content of 2%, two application levels were tested, one at a “lowaverage” use rate for the particular vegetable type in this soil, andthe other at ½ this rate. Sub-optimum use rates assist indifferentiating fertilizer effectiveness. These rates are indicated inTable 15 as either “100%” or 50%.” The 100% quantity for a particularvegetable is set out in parenthesis under the name of the vegetable. Thefertilizer was applied in four divided applications, one at planting andthe others at 7, 14 and 21 days post emergence, the post emergenceapplications were side-dressed. All plants were watered by sprinklerirrigation using non-chlorinated water. Harvesting was done manually.Results are listed in Table 15.

TABLE 15 YIELDS (tons/acre) BIO-6-33 BIO-6-3-3 CK-6-3-3 CK-6-3-3VEGETABLE (100%) (50%) (100%) (50%) Tomatoes 24.0 21.3 18.1 11.0 (1600lbs) Carrots 32.2 28.0 18.2 14.1 (1200 lbs) Cabbage 51.8 45.3 38.0 26.9(1200 lbs) Cauliflower 9.4 8.8 6.2 5.1 (1200 lbs) Potatoes 28.0 26.816.6 12.0

The data of Table 15 are evidence that the BIO-6-3-3 formulation of thepresent invention significantly out-performs the control CK-6-3-3fertilizer. In addition to significantly higher yields at 100% userates, the BIO-6-3-3 product shows significantly less reduction in yieldwhen used at the 50% level compared to the control formulation,CK-6-3-3.

Example #5

Improved Rice Yields—Field Trial

The formulation of Example #2 (referred to as BIO-8-4-8) was used inrice farming as a booster fertilizer to supplement urea, the usualsource of nitrogen. All experimental plots were one hectare square, allwere irrigated, all were planted with paddy rice variety IR-64transplanted from a nursery plot at 21 days. In all BIO-8-4-8 plots,said product was applied at 110 kg/ha, one time at transplanting. Ureawas applied at three different rates: 240 kg/ha (100%), 180 kg/ha (75%),and 120 kg/ha (50%). The 110 kg of BIO-8-4-8 supplied 2.64×10̂12 cfu, or2.64 trillion cfu, of Bacillus microorganisms and 38.5 kg ofdecontaminated layer chicken manure per hectare. Control plots receivedurea as the only fertilizer. The rice was harvested after 83 days (posttransplanting) and yields were reported in metric tons per hectare(mt/ha). The results are listed in Table 16.

TABLE 16 % N (from urea) Control (mt/ha) BIO-8-4-8 (mt/ha) % Improvement100%  8.55 9.55 11.7 75% 8.38 9.25 10.4 50% 8.31 9.15 10.1The data listed in Table 16 are evidence that the product known asBIO-8-4-8 significantly improved rice yield at all three levels ofnitrogen. The production of rice in developing countries is extremelycost sensitive, many farmers have no choice but to use less than optimalnitrogen levels. The present invention can help to improve yield wheneither 100% N or less is used.

Example #6

Fruit Tree Yields—Field Trial

The formulation of Example #3 was used to enhance the yield of fruittrees when used as a side-dress at the base of trees. Five hundred gramswas applied per tree per month for six months starting one month priorto budding. The product (referred to as BIO-30-1-1) is watered-inimmediately after application. The effect is measured as an improvementin fruit yield Tests were run at commercial operations and noconventional practice was changed to accommodate the BIO-30-1-1 product,results are reported from 100 trees treated with BIO-30-1-1 vs. 100untreated, control, trees for each fruit tree listed. The results arelisted in Table 17.

TABLE 17 Yield - BIO-30-1-1 Yield - Untreated Tree Type (Bushels/100Trees) (Bushels/100 Trees) Apple (Granny Smith) 520 405 Apple (RedDelicious) 512 422 Pear (Bartlett) 372 291 Peach 506 390 Apricot 292 207Almond 5,800 lbs 4,210 lbsThe data of Table 17 are evidence that multiple applications of theinventive product known as BIO-30-1-1 significantly improves fruityield. The total application, over 6 months, of 3 kg of BIO-30-1-1provides 9×10̂10 (90 billion) total Bacillus spores and 900 grams ofdecontaminated layer chicken manure per tree.

It will be apparent to those skilled in the art that variousmodifications and alterations can be made in the above formulations,techniques and applications without departing from the scope of thepresent invention. Therefore, it is not intended that this invention belimited by the terms of the general disclosure presented above or by theexperiments and examples, but only by the claims that follow.

1-61. (canceled)
 62. A method of making a fertilizer compositioncomprising decontaminated manure and Bacillus spores, the methodcomprising the steps of: a) treating raw manure to form a decontaminatedmanure; and b) combining the decontaminated manure with a secondcomposition comprising Bacillus spores to produce the fertilizercomposition.
 63. The method of claim 62 comprising a step (c) of formingthe fertilizer composition into prills or pellets, and adding humic acidas a hardening agent, either in the second composition of step (b), oradded during said step (c).
 64. The method of claim 63 wherein the humicacid is selected from the group consisting of leonardite and potassiumhumate.
 65. The method of claim 62 wherein step a) comprises contactingthe raw manure with a hypochlorite compound selected from the groupconsisting of calcium hypochlorite, sodium hypochlorite, and mixturesthereof.
 66. The method of claim 65 wherein the hypochlorite compound isadded at about 0.5 to about 3.0 percent by weight of dry ingredients.67. The method of claim 62 wherein the second composition comprisingBacillus spores is prepared as a water suspension prior to step (b). 68.The method of claim 62 wherein step a) comprises contacting the rawmanure with a mineral acid selected from the group consisting ofhydrochloric acid, sulfuric acid, phosphoric acid, nitric acid, andcombinations and mixtures thereof.
 69. The method of claim 68 whereinthe mineral acid is added in sufficient quantity to reduce pH of thepartially decontaminated manure below 3.0.
 70. The method of claim 62wherein step a) comprises a pit composting process, the pit compostingprocess running for a period of time ranging from about 2 to about 3years.
 71. A process according to claim 62 wherein step a) comprises adrying process running for a period of time long enough to render amoisture content of the substantially decontaminated manure below 20percent.
 72. A process according to claim 71 wherein the drying processis a solar drying process.
 73. A method of making a fertilizer product,the method comprising the steps of: a) producing a decontaminatedmanure; b) combining the decontaminated manure of step (a) with a secondcomposition comprising Bacillus spores to produce a fertilizercomposition; c) adding humic acid from an external source to thefertilizer composition to form a modified fertilizer composition; and d)forming the fertilizer product from the modified fertilizer compositionunder conditions of temperature and pressure suitable to produce theproduct.